Rotate the tensioner plunger 90 degrees in its bore and compress the plunger.

Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.

Install the balance shaft drive chain tensioner and bolts.

Remove the paper clip from the balance shaft drive chain tensioner.

Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.

WARNING

There are 3 colored links on the timing chain. 2 links are of matching color, and 1 link is of a unique color. Use the following procedure to line up the links with the actuators. Orient the chain so that the colored links are visible.

Fig. Camshaft alignment

Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.

Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link

Fig. Camshaft actuator and timing chain mark alignment

Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses.

Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.

Hand tighten the new intake camshaft actuator bolt.

Route the timing chain around the crankshaft sprocket and line up the first matching colored link with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.

Fig. Crankshaft sprocket and timing chain mark alignment

Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.

Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt.

The timing chain tensioner is released by compressing it 0.079 inch (2 mm), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.

Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt.